Granite parquetry tile assembly method

ABSTRACT

A method of assembling a tile, including: cutting a stone strip into a plurality of stone shapes; assembling said plurality of stone shapes in a tray comprising a non-stick coating and a temporary adhesive applied thereto for temporarily securing said plurality of stone shapes in a predetermined pattern; applying a resin between the assembled plurality of stone shapes and curing said resin to bond said stone shapes into a tile; removing said tile from said tray; and polishing said tile.

FIELD OF THE INVENTION

The present invention relates to a granite tile assembly method. Inparticular, the present invention relates to a method for assemblinggranite pieces into a decorative parquetry tile.

BACKGROUND OF THE INVENTION

The prior art reveals a number of methods for assembling individualstone materials into a singular finished tile comprising a pattern, forexample a mosaic or a decorative pattern.

As part of the assembly methods of such tiles, stone material isprearranged and secured in place during a bonding process wherein resinor adhesive is used to permanently join the stone material piecestogether to form a singular tile. Such steps generally require a frameor jig structure which maintains a spacing between the individual stonepieces to allow a resin to be injected and cured therebetween. However,the use of the frame or jig structure becomes more complex to constructas the complexity of the pattern increases. In other methods, theplacement of stone pieces is achieved by bonding these pieces in apredetermined position to a backer plate prior to bonding the stonepieces together with a resin. The use of such a backer plate is toensure that the stone pieces do not shift during curing or resin appliedbetween them and distort the final tile design. However, backings usedto provide structural support and fixation add additional material, costand weight to a tile and require additional steps in the manufacturingprocess.

For example, US Patent Publication 2006/0175000 (OSTERWALDER) disclosesthe use of an adhesive sheet, which is preferably water-soluble paper,onto which are positioned tiles, whereby this adhesive sheet is removedby means of water. As such, the need to use water adds an additionalstep, which increases costs. Also, it is not possible to use resin insuch tiles as the mix of water and resin is not compatible.

Other prior art documents require the use of vacuum to restrain tilesplaced on a jig, which increases costs.

What is therefore needed is a tile assembly method that employs a simpleframing structure for producing a less costly and lighter tile.

SUMMARY OF THE INVENTION

In accordance with a present embodiment of the present invention thereis provided a method of assembling a tile, comprising: cutting a stonestrip into a plurality of stone shapes; assembling said plurality ofstone shapes in a tray comprising a non-stick coating and a temporaryadhesive applied thereto for temporarily securing said plurality ofstone shapes in a predetermined pattern; applying a resin between theassembled plurality of stone shapes and curing said resin to bond saidstone shapes into a tile; removing said tile from said tray; andpolishing said tile.

BRIEF DESCRIPTION OF THE DRAWINGS

In the appended drawings:

FIG. 1 is a top view of a parquetry tile, in accordance with anillustrative embodiment of the present invention;

FIG. 2 is a flowchart of a method of assembling the parquetry tile ofFIG. 1, in accordance with an illustrative embodiment of the presentinvention;

FIG. 3 is a perspective view of a tray used for assembling the parquetrytile of FIG. 1 illustrating the deposition of a temporary adhesivethereon;

FIG. 4A is a top view of the tray of FIG. 3 illustrating the dispositionof adhesive relative to the various pieces of stone to be assembled;

FIG. 4B is a partial and more detailed view of FIG. 4A; and

FIG. 5 is a cross-sectional view along line 5 of the parquetry tile ofFIG. 1, in a tray illustrating the adhesive used to temporary adhere thepieces to the tray and the resin used to bond the pieces together.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

The present invention is illustrated in further detail by the followingnon-limiting examples.

Referring now to FIG. 1, and in accordance with an illustrativeembodiment of the present invention, there is provided a stone tile 10comprising a plurality of individually pre-cut stone pieces as in 12.The tile 10 illustratively comprises a parquetry design formed by thebonding of the variety of pre-cut stones as in 12 together using a resinor epoxy adhesive 14 applied between the spaces of the pre-cut stones asin 12. The pre-cut stones as in 12 illustratively comprise a variety ofshapes such as triangles, squares, rectangles, trapezoids, or othershapes that are used in formation of a parquetry design. Illustratively,the pre-cut stones as in 12 may be any variety of stone such as granite,marble, limestone, other building stones or combination, having any typeof texture and colour and which is generally known to have a hardnessand toughness for the use in tiling applications. Depending on theapplication, for instance the use of the tile 10 in flooring or fordecorative murals, the tile 10 is sized accordingly. Illustratively, thetile 10 may comprise a square dimension having a length and a width ofapproximately 24 inches and a thickness of about 0.5 inches. Of note,other sizes, shapes, thicknesses, widths, may be provided for inaddition to the use of other materials such as woods, plastics, andmetals, in the formation of the tile 10. Additionally, other patternsand geometric configurations of the pre-cut stones as in 12 may beprovided for forming the decorative tile 10.

Now referring to FIG. 2, in addition to FIG. 1, in accordance with anillustrative embodiment of the present invention, there is provided aMethod of Assembly 16 of the tile 10, generally comprising a series ofsteps as will now described. As part of the Method of Assembly 16, aPre-cutting 18 of an unprocessed rough stone block (not shown)illustratively comprises cutting the stone block to various sizes andshapes as depending on the design of the final assembled tile 10.Illustratively, an unprocessed stone is cut into strips of between ⅜ and1.25 inches widths by a block saw (not shown) as is generally known inthe art. The strip is then fed into a trimming saw which cuts the slabinto smaller geometric pieces, such as a rectangular piece as in 12 ₁,or a triangular piece as in 12 ₂, or any other pre-cut stones as in 12that have be sized and shaped so as to form a parquetry patterned tile10.

Now referring to FIG. 3, in addition FIG. 1 and FIG. 2, the pre-cutstone pieces 12 are arranged in a tray 20 as part of an Arrangement 22step. The tray 20 is illustratively a square shape comprising a depthand lengths that is capable of receiving the pre-cut stone pieces as in12 therein in addition to accommodating the resin or epoxy adhesive 14that is applied between the pieces 12 at a later step for bonding thepieces as in 12 together to form the singular tile 10. Preferably, amould release agent or anti-stick spray is used. The tray 20 isillustratively comprised of a high density plastic polymer material suchas polyethylene or the like that generally will not adhere to resinepoxy and is resistant to the application of heat during a curing of theresin or epoxy adhesive 14 along with the degradation due to the anycontact with chemical adhesives and resins. Alternatively, a metallictray coated with such a plastic material may also be provided for. Ofnote, while the tray 20 is illustratively shown to accommodate thepre-cut stone pieces as in 12 for forming a single square tile 10, thetray 20 may also illustratively comprise a shape that accommodates morethan one such square tile 10, for instance a rectangular shape that canaccommodate the stone pieces as in 12 for two or more tiles 10. In theillustrated example, the tray 20 accommodates three tiles 10 by threetiles. Other configurations could be simple a row of three to six tileslong by one tile high. Still additionally, the tray 20 may betriangular, or circular, or the like for accommodating a tile 10 ofdifferent geometries.

Now referring to FIGS. 4A and 4B, in addition to FIGS. 2 and 3, prior toassembling the stone pieces as in 12 within the tray 20, the tray isCoated 24 with an anti-stick coating 26 such as Teflon™ or a knownnon-stick plastic or silicon that generally resists a permanent bondingof a resin or epoxy or grout thereto during a later step of the Methodof Assembly 16. Then, a temporary adhesive 28 is Applied 30 in lines orbeads to the tray 20 so that the pieces 12 to be assembled within thetray 20 are temporarily held in place within the tray 20 by thetemporary adhesive 28, such as contact glue, during the subsequentassembly steps. Illustratively, the anti-stick coating 26 and adhesivemay be applied to the tray 20 by an automated process, such as a roboticarm system or the like.

In some embodiments, Applicant has discovered that the use of thetemporary adhesive 28 may not be necessary. For example, if the spacingbetween the pieces 12 in the tray is small enough, then it is possiblethat the pieces 12 will stay in place without the need of the temporaryadhesive 28.

Still referring to FIGS. 2, 3, 4A, and 4B the pre-cut stone pieces as in12 are then Arranged 32 into a decorative arrangement within the tray20, for instance by a robotic arm or the like. The temporary adhesive 28adheres to the underside of the pre-cut stone pieces as in 12 totemporarily prevent the movement of the pieces 12 within the tray 20during the remaining assembling procedure.

Still referring to FIGS. 4A and 4B, in addition to FIG. 3, an epoxyresin 34, or the like is Applied 36 to fill the voids 38 betweenadjacent stone pieces as in 12 and cured to thereby form a permanentbond between such adjacent pieces as in 12, and thus a single stone tile10. Part of the epoxy resin 34 may be applied to the top of the stonepieces 12. As the tray 20, made of high density plastic polymer materialwhich resists adhering to resin, has been coated with an anti-stickcoating 26, any epoxy resin 34 that seeps through the voids 38 betweenthe stone pieces as in 12 to contact the tray 20 will not form apermanent bond therebetween to ensure that the bonded pieces as in 12can be easily removed from temporary engagement with the tray 20. Theepoxy resin 34 may illustratively be thermoset resin, such asMarine-Tex™, comprising high strength properties which is easy to apply,strong and permanent when cured and which can be painted or sealed.Illustratively, the epoxy resin 34 has an adhesive shear strength ofabout 4,000 psi and can be mixed, applied and cured at roomtemperatures, is workable for about 25-35 minutes and cures and hardensin 2-3 hours with a full cure taking 18-24 hours. If desired the curingtime can be reduced by applying heat. Once cured, the pre-cut stonepieces as in 12 form a solid singular tile 10.

Now referring back to FIG. 2, in addition to FIG. 1, once the epoxyresin 34 has cured, the tiles 10 are Removed 40 from the tray 20. Thebonds formed by the anti-stick coating 26 between the tray 20 and thepre-cut stone pieces 12 are easily broken and any excess resin 34contacting thereto does not stick to the tray 20. Once removed, the tile10 is advantageously polished as one unitary tile 10 thereby evening anydifferences between adjacent pre-cut stone pieces as in 12 and removingany resin and/or adhesive, or epoxy according to methods as aregenerally known in the art, by pneumatic polisher for instance. It alsoprovides for an exact thickness of a tile. Illustratively, the tile 10may be polished in a polishing line. The tiles 10 are Cut 42 intoindividual tiles 10 and finished. As a result of the method, a finishedunitary parquetry 10 tile is formed.

1. A method of assembling a tile, comprising: assembling a plurality ofstone strips in a tray comprising a non-stick coating and a temporaryadhesive applied thereto for temporarily securing said plurality ofstone strips in a predetermined pattern; applying a resin between theassembled plurality of stone strips and curing said resin to bond saidstone strips into a tile; removing said tile from said tray; andpolishing said tile.
 2. The method of claim 1, wherein the non-stickcoating includes Teflon.
 3. The method of claim 1, wherein the non-stickcoating includes a non-stick plastic or silicone or a resin compatiblemould release agent.
 4. The method of claim 1, wherein the temporaryadhesive includes contact glue.
 5. The method of claim 1, wherein theresin comprises epoxy resin.
 6. The method of claim 4, wherein the epoxyresin has an adhesive shear strength of about 4,000 psi.
 7. A method ofassembling a tile, comprising: cutting a stone strip into a plurality ofstone shapes; assembling said plurality of stone shapes in a traycomprising a non-stick coating and a temporary adhesive applied theretofor temporarily securing said plurality of stone shapes in apredetermined pattern; applying a resin between the assembled pluralityof stone shapes and curing said resin to bond said stone shapes into atile; removing said tile from said tray; and polishing said tile.
 8. Themethod of claim 7, wherein the non-stick coating includes Teflon.
 9. Themethod of claim 7, wherein the non-stick coating includes a non-stickplastic or silicone or a resin compatible mould release agent.
 10. Themethod of claim 7, wherein the temporary adhesive includes contact glue.11. The method of claim 7, wherein the resin comprises epoxy resin. 12.The method of claim 11, wherein the epoxy resin has an adhesive shearstrength of about 4,000 psi.
 13. A method of assembling a tile,comprising: assembling a plurality of stone strips in a tray comprisinga non-stick coating; securing said plurality of stone strips in apredetermined pattern; applying a resin between the assembled pluralityof stone strips and curing said resin to bond said stone strips into atile; removing said tile from said tray; and polishing said tile. 14.The method of claim 13, wherein the non-stick coating includes Teflon.15. The method of claim 13, wherein the non-stick coating includes aresin compatible mould release agent.
 16. The method of claim 13,wherein the non-stick coating includes a non-stick plastic.
 17. Themethod of claim 13, wherein the non-stick coating includes a non-sticksilicone.
 18. The method of claim 13, wherein the resin comprises epoxyresin.
 19. The method of claim 18, wherein the epoxy resin has anadhesive shear strength of about 4,000 psi.